Teacher DIY: Build a Wind Tunnel

This DIY resource for teachers will guide you through building your own Wind

Tunnel to use in class, or with our Wind Tunnel Lesson Plan.

Wind tunnels are a fun way for students to explore physics concepts

surrounding flight, air resistance, drag and aerodynamics. By rapidly creating

and testing designs for objects that sink, float, or hover in a wind stream,

students get immediate feedback on ideas, allowing for rapid refinements,

confidence trying new concepts and explorations of problems in an engaging

way.

This version is a cheap and easy way to create a wind tunnel from easily

accessible and workable materials.

Materials and Tools

These simple wind tunnels have three parts – the tunnel, the fan, and the fan stand. They can be

easily disassembled for storage. Pro Tip: Ask your local hardware store or woodwork teacher to cut the

timber to size, to save time.

Please ensure you follow your school WH&S procedures while constructing this equipment.

A. Pedestal fan (head and neck only), or box fan

B. 2 x 10mm wooden planks, 500x200mm

C. 1 x 10mm wooden plank, 500x500mm

D. 8 x screws (at least 30mm), and 4 washers

E. 4 x Zip ties

F. Clear packing tape

G. Gaffer tape

H. Saw

I. Clamp(s) or vice

J. Drill

K. Drill bits, screw driver, pencil, ruler

. Not Pictured: 1 x trellis wire or chicken coop wire,

1200x1200mm

Clear plastic sheet, totalling 1200x1200mm

area, like:

o Large garbage bags (try Bunnings),

o Vinyl tablecloth

o Large roll of cling wrap

Wire cutters and pliers

Build Steps

1. Mark and cut your timber planks to size.

Your large plank should be approximately the

diameter of your fan head, or a little larger. Our

fan was 490mm in diameter, so we used

500x500mm.

Your small planks will be attached perpendicular

to the large plank, to support the fan head. They

need to be wide enough to raise the back and

neck of the fan off the ground. We used

500x200mm.

2. On the large wooden plank, measure and mark 4

points 50mm in from the edges.

3. Clamp large board onto a surface suitable for

drilling.

4. Drill holes all the way through the wood at your

marked points.

Use a drill bit that is slightly smaller in diameter

than the screws you’ve got. We used a 4.0mm

bit, for 4.5mm screws.

5. Line up one 500mm edge of one small plank with

two of the marks on the large plank. On the thin

edge of the small plank, make corresponding

marks. Repeat with the second small plank. Each

small plank should have two marks on one

500mm edge that line up with your large plank.

6. Using the same sized bit, drill into the small

planks at least 20mm (this will depend on the

length of your screws!). We drilled in 20mm for

30mm screws.

7. Fix the small planks perpendicular to the large

planks using four screws.

8. Place the fan head on top of the stand, and

remove the front cover.

Pro Tip: make sure the fan is set to NOT rotate at

this point.

9. Mark two points on one side of the stand that

provide a gap through the back cover of the fan

to the stand.

10. Keeping these marks aligned, repeat on the

other side of the stand.

11. At these points, drill holes 20mm deep into the

stand (4 total).

12. With a washer between the screw and the fan

frame, fix the fan to the stand.

13. To maintain alignment, place the screws in all

four holes before tightening them.

14. Now your fan should be securely attached to the

frame.

15. Reattach the fan cover.

16. Cover the trellis wire on both sides using the

clear plastic. Use the clear packing tape to fix it

together.

17. Form a column using the wire, making sure it is

the same size as the circumference of the fan.

18. Tape the ends together, twist the wire together,

or do both.

19. Using wire cutters, make two 200mm cuts at the

base of the tunnel to create a flap.

20. Use gaffer tape along the flap to protect the open

wire edges.

21. Fold another 50mm piece of gaffer tape over the

rim about 20mm from the flap. This will become

a point to attach the fan to the tunnel.

22. Repeat on the other side of the flap, and at two

equidistance points on the rim of the tunnel to

create 4 attachment points in total.

23. Pierce a small hole through each piece of tape

that will become an attachment point.

24. Thread a cable tie through each.

25. Balance the tunnel on top of the fan, and secure

with the cable ties.

Your wind tunnel is complete! Turn it on and try it out!

Straighten any imbalances

Add extra cable ties if needed

Remove long edges of cable ties to prevent the

fan blades hitting them.

Points to consider

Cost The wind tunnel and base can be put together for about $80 while the fans can range anywhere

from $30 - $100. All up, this wind tunnel can be made for under $200.

Pros

Simple to make

Cheap and easy to source materials

Tunnel is collapsible for storage

Cons

Given the range of different plastics you could use for the tunnel, Steps 15-17 are fiddly. Do

what works best for you, and share your method with us!

Fans with blades can be dangerous, so care needs to be taken when students use them.

The wind strength of these tunnels is quite high. If the wind tunnel is too powerful, it can be

less challenging for students to create a floating prototype – try using the lowest setting to

make it a little harder and encourage creative solutions.

Alternatives If you want to create a more robust wind tunnel to use year after year, like

the wind tunnels we tour with (pictured right), you can download the CAD

files at the link above (you’ll need access to CNC machinery).

Safety

Edges of trellis wire are sharp, so ensure wire is covered with plastic

and packing tape.

Spinning fan blades can be dangerous so ensure supervision when

using with students and leave guards over fan blades.

If you have any questions regarding this teacher resource, contact the Smart

Skills team at QSSI@questacon.edu.au, and connect with us on Twitter and

Facebook.

If you would like to know more about our teacher professional development

opportunities, contact the teacher professional development team at

teachers@questacon.edu.au.